Perforating gun connector

ABSTRACT

Controlled Buoyancy Perforating technology for highly deviated and substantially horizontal wellbores may include long perforating guns assembled on a rig floor from a multiplicity of light weight and highly engineered shaped charge carrier joints. Tubular housings for such light weight joints may be fabricated from composite materials having steel transition collars. The collars are designed for an angularly coordinated, bayonet assembly and, in most cases, rapid disassembly. The internal volume of each joint is environmentally sealed by a plurality of O-rings. Barbs carried by collet fingers projecting from opposite ends of a sealing sleeve that externally bridges a transition collar union plane secures the union by meshing with detent channels in the respective collars. Individual shaped charge units and cooperative fusing are assembled in a light weight inner loading tube having an alignment collar to secure the angular and axial position of the loading tube relative to the transition collars.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Division of pending U.S. patent application Ser.No. 10/910,874 filed Aug. 4, 2004.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention generally relates to downhole well tools and specificallyto controlled buoyancy perforating methods and apparatus.

2. Description of Related Art

Traditional petroleum drilling and production technology often includesprocedures for perforating the wall of a production well bore into thefluid bearing strata to enhance a flow of formation fluid alongperforation channels. Depending on the well completion equipment andmethod, it is necessary for such perforations to pierce a wellborecasing, a production pipe or a tube wall. In many cases, the casing ortube is secured to the formation structure by a cement sheath. In suchcases, the cement sheath must also be pierced by the perforation channelas well.

There are three basic methods presently available to the industry forperforating wells. Those three methods are: a) explosive propelledprojectiles, b) pressurized chemicals and c) shaped charge explosives.Generally, however, most wells are perforated with shaped chargeexplosives. Accordingly, the preferred embodiment description of thepresent invention will be directed to shaped charge perforators.However, many of the invention characteristics may be adapted to otherperforation methods.

Shaped charge explosives are typically prepared for well perforation bysecuring a multiplicity of shaped charge units within the wall of asteel pipe section. The pipe section bearing the shaped charges may besupported from the wellhead at the end of a wireline, coiled tube,coupled pipe or drill string for location within the wellbore adjacentto the formation zone that is to be perforated by detonation of theshaped charges.

Collectively, a pipe section and the associated charge units will becharacterized herein as a “charge carrier.” One or more charge carriersmay be coupled serially, end-to-end, to provide a unitized gun section.A “perforating gun” may include one or more gun sections that are joinedby swivel joints. A perforation gun is merely one of many “bottom-holeassemblies” or bottom-hole tools the present invention is relevant to.

Each shaped charge unit in a charge carrier comprises a relatively smallquantity of high energy explosive. Traditionally, this shaped chargeunit is formed about an axis of revolution within a heavy steel case.One axial end of the shaped charge unit is concavely configured. Theconcave end-face of the charge is usually clad with a thin metallicliner. When detonated, the explosive energy of the decomposing charge isfocused upon the metallic liner. The resulting pressure on the linercompressively transforms it into a high speed jet stream of linermaterial that ejects from the case substantially along the charge axisof revolution. This jet stream penetrates the well casing, the cementsheath and into the production formation.

A multiplicity of shaped charge units is usually distributed along thelength of each charge carrier. Typically, the shaped charge units areoriented within the charge carrier to discharge along an axis that isradial of the carrier longitudinal axis. The distribution pattern ofshaped charge units along the charge carrier length for a vertical wellcompletion is typically helical. However, horizontal well completionsmay require a narrowly oriented perforation plane wherein all shapedcharge units within a carrier section are oriented to discharge insubstantially the same direction such as straight up, straight down oralong some specific lateral plane in between. In these cases, selectedsections of charge carriers that collectively comprise a perforation gunmay be joined by swivel joints that permit individual rotation of arespective section about the longitudinal axis. Additionally, eachcharge carrier may be asymmetrically weighted, for example, to orient apredetermined rotational alignment when the gun system is horizontallypositioned.

Controlled Buoyancy Perforating (CBP) allows the use of long perforatinggun sections in horizontal and extended reach wells by reducing theweight and increasing the buoyancy of the perforating equipment.Reduction of the gun weight correspondingly reduces the bearing weightof the gun against the horizontal segments of the borehole wall andhence, the frictional forces opposing axial movement of the gun stringalong the well bore length. CBP objectives are accomplished by acombination of designs and materials such as composite material carriertubes, caseless perforation charges and foamed material charge holders.Other inventions and innovations that pertain to Controlled BuoyancyPerforating (CBP) are described in U.S. patent application Ser. No.10/696,697 which is incorporated herein by reference.

Although the thrust of CBP is focused upon reductions of the gun weight,the requirements of internal seal integrity from an external fluidpressure environment and rapid assembly and disassembly on the rig floorremain the same as known to the prior art. Also imperative of CBP is arig floor assembly system that confidently maintains a predeterminedangular orientation of the perforation charges.

Prior art perforating guns are, generally, a serial assembly of chargecarriers, end-to-end, in 30 ft. to 90 ft. segments. As the longitudinalaxis of a charge carrier segment is suspended vertically from a derrickcrown block, the lower end of the segment is aligned with the upper endof a tool string or preceding charge carrier segment that is suspendedvertically within the well bore from the rig floor; usually by a slipaccessory in the rotary drive table. A threaded end connector joins theadjacent ends of the axially aligned segments when either segment isrotated relative to the other about the longitudinal axis common toboth.

Although threaded steel carrier connections as previously described aresuitably strong for supporting the enormous weight of a steelperforating gun, the incremental assembly process is relatively slow.CBP technology greatly alleviates these joint loads on a gun assembly.Where a 5 in. conventional steel perforating gun may weigh in excess of14 lb/ft., a similar, CBP composite material system may weigh only 4lb/ft. A 5,000 ft. long perforating gun having a weight distribution ofonly 4 lb/ft. requires the upper end connectors to support a 20,000 lbair weight load. As a CBP gun is lowered into the well and the gunweight is supported by the displacement forces of the wellbore fluid,the tensile loads on the connectors and connector threads is negligible.However, after the gun is discharged, the gun buoyancy is dramaticallyreduced by the consequential flooding of the internal gun volume. Hence,even though CBP technology may reduce the stress demands on a chargecarrier connection, significant strength requirements remain.

One of the driving objectives of CBP, therefore, is to place extremelylong perforating guns in substantially horizontal production bores.Reduction or elimination of the rotational steps in the charge carrierassembly process could greatly accelerate the perforating gun assemblyprocedure.

It is an objective of this invention, therefore, to provide a bayonetjoint connection between charge carrier joints that requires norotation.

Another objective of this invention is a rapidly assembled bayonetconnection between charge carrier joints that maintains a predeterminedangular orientation between the joints.

Also an object of this invention is a steel connecting collar betweennon-metallic housing tubes for charge carrier joints.

A still further object of this invention is a method and apparatus forrapid preassembly of an inner loading tube within an outer carrierhousing that requires no intermediate booster assembly.

BRIEF SUMMARY OF THE INVENTION

These and other objects of the invention as will emerge from thefollowing Detailed Description are addressed by a perforating gun thatis particularly suited for controlled buoyancy perforating. Theperforating gun of the present invention comprises the end-to-endassembly of two or more charge carrier joints. Each joint comprises aninner loading tube that directly supports the shaped charge units andthe cooperative detonation elements. For buoyancy contribution, theinner loading tube may be formed of a light weight material such asfoamed plastic. However, at a chosen point along the length of the innerloading tube and around the loading tube circumference, a firm referencesurface is secured to the loading tube structure.

The inner loading tube is nested coaxially within an outer housing tube,the internal volume of which is for environmental isolation fromwellbore fluids and other contaminants. Also for controlled buoyancycontribution, the outer housing tube may be fabricated of high strength,non-metallic materials such as composites with glass or carbon fiber.

To support the stress concentrations at the union point between a pairof joint ends, a composite or other non-metallic housing tube may beterminated by metallic, i.e. steel, transition collars.

Near one end of a charge carrier joint, preferably combined with atransition collar, a reference surface is provided to accommodate thereference surface of the inner loading tube. The inner loading tube musthave the required orientation about the housing axis for the tworeference surfaces to correctly engage. Additionally, engagement of thetwo reference surfaces secures the relative position proximity betweenthe two detonation boosters of a union between two charge carrierjoints. As the joint union is angularly controlled, the respectivecarrier joint ends to a union are assembled, generally, with a bayonetmotion sequence comprising rotational alignment, compressive translation(lapping) and latching.

In one embodiment of the invention, a charge carrier joint may comprisesteel transition collars secured to opposite ends of a reinforcedplastic or composite material housing tube. Angular orientation betweenthe two collars of a union is maintained by alignment pins that bridgethe union interface to penetrate prepositioned alignment bores or pinsockets. The union is environmentally sealed by a first set of O-ringsbetween an internal sleeve and the internal bore of a transition collar.A second set of optional or redundant O-ring seals is provided betweenthe external surface of the transition collar and the internal surfaceof a cylindrical connector sleeve.

The connector sleeve has an axially sliding fit around the outerperimeter of the transition collars. Collet fingers projectlongitudinally from each end of the connector sleeve and each finger hasa barbed end for meshing with a detent channel around the perimeter ofeach collar. When two joints of a union are axially pressed together,e.g. “lapped”, the collet finger barbs enter the respective detentchannels to prevent opposite direction separation e.g. “latched”.Preferably, a keeper ring that encompasses the circumference of thecollet fingers is slidably translated over the finger ends when thebarbs are meshed with the detent channel.

Selective separation may be accomplished by translating or cutting thekeeper ring to remove the belting function around the collet fingers. Atool is used to lift and hold all of the barbs in a respective detentchannel out of the channel until sufficient axial translation occurs toprevent return to the detent channel.

An annular seating plane is provided internally of each transitioncollar to receive an alignment collar secured to each inner loadingtube. The inner loading tube is a unitizing element for all of theshaped charges and ignition fuse in a carrier joint. A loading tubecollar reference plane contiguously abuts the transition collar seatingplane to longitudinally locate the exact position of the detonationbooster elements at each end of an inner loading tube. A threadedsetting ring or resiliently biased snap-ring secures the tightengagement of the loading tube collar reference plane against thetransition collar seating plane, An orientation pin or key secures thecorrect angular orientation of the inner loading tube with respect tothe charge carrier axis.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The invention is hereafter described in detail and with reference to thedrawings wherein like reference characters designate like or similarelements throughout the several figures and views that collectivelycomprise the drawings. Respective to each drawing figure:

FIG. 1 is a schematic earth section illustrating a deviated wellborehaving a substantially horizontal fluid bearing strata.

FIG. 2 is a is a wellbore cross-section as seen from the FIG. 1 cuttingplane 2-2 illustrating the present invention perforating gun buoyedagainst the upper wall elements of the wellbore wall.

FIG. 3 is a half-section of a pair of charge carrier joints at themutual end connection according to the invention.

FIG. 4 is a detail section of the FIG. 3 joint connection showinginitial placement of a disassembly tool.

FIG. 5 is a detail section of the FIG. 3 joint connection showing aconnector release.

FIG. 6 is a detail section of the FIG. 3 joint connection showing anaxial separation of a joint connection.

FIG. 7 is an expanded half-section of an outer housing tube and anun-attached transition collar.

FIG. 8 is a half-section of an outer housing tube in partial combinationwith a cooperative transition collar.

FIG. 9 is a half-section of an outer housing tube in full combinationwith a cooperative transition collar.

FIG. 10 is an axially exploded pictorial of the FIG. 3 embodimentillustrating the major independent components of the connection.

FIG. 11 is a half-section view of an alternative embodiment of theconnection between the transition collar and the outer housing tube.

FIG. 12 is a detail section of the FIG. 11 area enclosed by the dashedline XII.

FIG. 13 is a half-section of a pair of charge carriers joined by asecond connector embodiment.

FIG. 14 is a pictorial view of the FIG. 13 connector embodiment.

FIG. 15 is an axially exploded pictorial of the FIG. 13 embodiment.

FIG. 15A is a pictorial view of an alternative embodiment of a taperedfit internal sealing tube.

FIG. 16 is a pictorial view of a third embodiment of the invention.

FIG. 17 is a half-section view of the third invention embodiment.

FIG. 18 is an axially exploded pictorial view of the third embodiment.

FIG. 19 is an axially exploded pictorial view of a modification of thethird embodiment.

FIG. 20 is a half-section view of a fourth embodiment of the invention.

FIG. 21 is a pictorial view of the fourth invention embodiment.

FIG. 22 is a detail section of the FIG. 20 area enclosed by the dashedline XXII.

FIG. 23 is an axially exploded pictorial view of the fourth inventionembodiment.

FIG. 24 is an axially exploded pictorial view of a modification of thefourth invention embodiment.

FIG. 25 is a half-section view of a fifth embodiment of the invention.

FIG. 26 is an axially exploded pictorial view of the fifth inventionembodiment.

FIG. 27 is a half-section view of a charge carrier joint having an innerloading tube secured therein.

FIG. 28 is an axially exploded pictorial view of inner loading tube ofthe invention.

DETAILED DESCRIPTION OF THE INVENTION

For environmental reference, FIG. 1 represents a cross-section of theearth 10. Below the earth surface 12, the earth firmament comprises anumber of differentially structured layers or strata. For the presentpurposes, a thin and mildly sloped strata 14 is represented to be ofparticular interest due to an abundant presence of petroleum.

From a drilling/production platform 16 on the earth surface 12, anextended wellbore 18 is drilled into and along the strata 14. In thiscase, the wellbore 18 is drilled to follow the bottom plane of thestrata.

There are many well completion systems. Although the present inventionis relevant to all completion systems in one form or another, the “casedhole” completion represented by FIG. 2 serves as a suitable platform fordescribing the presently preferred embodiments of the invention.

With respect to FIG. 2, the borehole 18 along the production strata 14is lined by casing 20 set within a cement sheath 22. In the course ofdrilling and/or casing, the borehole 18 and ultimately, the casing 20,is flooded with fluid. Usually, the fluid is liquid and the liquidusually includes water. In some wells, however, the fluid is natural gasor oil. The presently described example of a preferred inventionembodiment proceeds with the assumption of a liquid environment 24within the well casing 20.

After the wellbore 18 is cased, the casing 20 and cement sheath 22 mustbe perforated to allow fluid production flow from the strata 14 into thecasing interior and ultimately, into a production tube not shown.Typically, the casing, cement sheath and formation are perforated by amultiplicity of shaped charge jets as represented by the convergingdashed lines 32 of FIG. 2. The mechanism of such perforations may be aperforation gun 30 according to the present description.

Typically, a perforating gun 30 is an assembly of several shaped chargecarrier sections or joints. Coaxially aligned, adjacent charge carriersections or joints may be joined end-to-end by connectors. Longperforating guns are normally assembled in “joint” increments ofapproximately 20 to 30 ft. length. In the parlance of the art, a “joint”of pipe is about 30 ft. long. A “stand” of pipe is normally about 90 ft.or three, pre-assembled “joints”. The “stand” length is a function ofthe derrick height that is, nominally, 100 ft. When drilling, i.e. whenthe depth or length of the borehole is being increased, drill pipe isadded to the drill string in lengths corresponding to the length of thesquare-sided Kelly pipe which is the drive link between the rotary tableand the drill pipe string. Normally, a Kelly pipe length corresponds tothe length of one drill pipe joint or, about 30 ft. When the drillstring is withdrawn from the wellbore, and hence, returned, however, therotary table is not engaged and the Kelly pipe is removed from the pipestring. Consequently, the pipe string may be assembled or disassembledmore rapidly with individually handled pipe sections that are 90 ft.“stands” rather than as a 30 ft. “joint”.

While the length of a charge carrier joint is not restricted to thelength of a Kelly pipe, there are material handling practicalities to beobserved in the rig floor assembly of a perforating gun that may begreater than a mile long. Hence, the length of a single, i.e. integral,charge carrier joint is often restricted to about 20 to 30 ft. A longperforating “gun”, therefore, is the end-to-end connected assembly ofnumerous charge carrier “joints”. The half-section of FIG. 3 representsthe mutual assembly of two charge carrier joints 34 by a connector 40into a unified perforating gun 30.

When oriented perforation is desired for a perforating gun stringcomprising numerous charge carrier sections, carrier section groups maybe linked by swivel joints for relative rotation about a longitudinaltube axis to facilitate gravity orientation. However, positive indexingstructure is necessary to maintain the required spatial and angularrelationship between the several shaped charge joints within a sectionand the means or device that determines the vertical or horizontal planefor the section.

Referring to FIGS. 2 and 3, charge carrier joints 34 respective to thepresent invention broadly comprise an outer carrier housing 36 and aninner loading tube 38. The outer carrier housing 36 is the exoskeletonof the assembly that carries the suspended weight stress andenvironmentally protects the explosive material within the inner loadingtube 38 from destructive contamination by wellbore fluid. Adjacent endsof serially adjacent carrier joints 34 are preferably joined by abayonet connector 40. An angular indexing device or mechanism such as adowel pin 88 secures the angular orientation of adjacent carrier joints34 relative to a common reference radian from the carrier jointlongitudinal axis 44.

The structurally independent inner loading tube 38 directly seats andconfines the several shaped charges in a carrier joint 34 to the desiredalignment relative to the reference radial from the longitudinal axis 44of the loading tube. The inner loading tube 38 has an assembly interfacewith the connector mechanism to secure angular orientation of theloading tube 38 relative to the outer carrier housing 36. Additionally,the respective lengths of the inner loading tube 38 and the outercarrier housing 36 are coordinated and relatively confinedlongitudinally to assemble adjacent detonation boosters 46 respective toadjacently connected charge carrier joints 34 within ignition proximitysimultaneously with a bayonet assembly of the outer carrier housings 36.

A preferred embodiment of an outer carrier housing 36 comprises acomposite material tube 50 having metallic transition collars 60 forinterfacing the composite material tube 50 with cooperative steelconnectors 40. The composite housing tube 50 of FIG. 3 may comprise anoriented alignment of glass fiber, polyaramid, carbon or other fiber ina polymer bonded composition to create the desired buoyancycharacteristics. The anticipated depth, pressure and temperature of thewell often determines the fiber, the fiber orientation, the polymer andthe wall thickness used for the housing tube 50 fabrication. At each endof a housing tube joint, connector meshing channels 52 are turned ormolded into a reduced O.D. end-segment 54.

The transition collar embodiment 60 of FIGS. 3 through 10 comprises ametallic, usually a malleable steel, swaging skirt 62 extending from abody ring 64. As fabricated and before installation on the end of ahousing tube 50, the swaging skirt 62 is conically flared about thecollar axis 44. The inside face of the swaging skirt 62 is formed withcircumferential ring lands 66 that are sized and spaced to mesh with thechannels 52 in the end segment 54 of the housing tube 50. Also extendingcircumferentially from the base ring 64 and in generally coaxialalignment with the swaging skirt 62 is an inner mandrel ring 68.

Assembly of the transition collar 60 with carrier housing tube 50comprises deformation of the flared swaging skirt 62. With respect to acomparison between the swaging skirts 62 illustrated by FIGS. 7 through9, respectively, it is seen that the flared skirt 62 of FIG. 7 has beendeformed from the originally fabricated conical geometry into thecylindrical geometry of FIG. 9. This deformation compresses thecomposite material end-segment 54 of the housing tube 50 between theinner mandrel ring 68 and the outer swaging skirt 62. An intermediatemoment in the deformation process (swaging) is shown by FIG. 8 as theconical base of the skirt 62 is compressed toward a cylindrical form.The ring lands 66 extended from the inside surface of the skirt 62 aremeshed into the ring channels 52 in the housing tube 50 thereby securingthe transitional collar 60 to the housing tube 50. For greater strength,the exterior surface of the housing tube end-segment 54 or the insidesurface of the skirt 62 may be coated with a bonding polymer such asepoxy prior to the skirt swaging. Subsequent to swaging, the polymer iscured. Any stress analysis of this transition collar embodiment shouldalso consider the “work hardening” contribution of swaging whichnormally tends to increase the collar tensile strength.

In this FIG. 3 embodiment of the invention, the transition collar bodyring 64 further includes the surface of an interior ring ledge 70 thatseats the inner loading tube 38 at a longitudinal reference positionrelative to the housing tube 50 length. An alignment collar 48 that isfirmly secured to the loading tube 38 is clamped between the seatingledge 70 and a threaded seating ring 76 to secure the longitudinalposition of the loading tube 38 relative to the axial length of thecharge carrier. A key slot 72 in the seating ledge 70 accommodates ashear key 45 that also penetrates a key aperture 56 in the alignmentcollar 48. The key slot 72 is positioned as a reference radial to securethe loading tube 38 from axial rotation relative to the housing tube 50.Discharge orientation of the shaped charges that are set in the loadingtube 38 is fixed, angularly, with respect to the key aperture 56.

The inside surface 78 of the transition collar 60 between the settingring threads 75 and the collar end 79 is preferably smooth toaccommodate O-ring seals 77 between the transition collar surface 78 andan internal sealing sleeve 82.

As an integral element of an internal sealing tube 80, the sealingsleeve 82 extends in opposite directions, axially, from an externalspacing ring 84. The spacing ring 84 is either notched or bored with adowel pin aperture 86 to accommodate traversal of an alignment pin 88that penetrates the radial alignment bores 90 respective to thecooperatively connected transition collars 60.

Holding the ends of adjacent charge carrier joints 34 together, axially,is a connector sleeve 100 comprising a cylindrical mid-body portion 102and integral collet fingers 104. The inside surface 106 of the mid-bodymay be relatively smooth to accommodate an axially sliding sealengagement with O-ring seals 108. A latching mechanism comprisesterminal barbs 110 at the opposite distal ends of the collet fingers104. The barbs 110 are formed with an abutment face that engages acooperative side-wall face of a detent channel 114 formed about theoutside perimeter of the transition collar 60. The distal end-face 116of each barb 110 is preferably tapered to accommodate the wedge of adisassembly tool 92. When the resiliently biased collet fingers 104 havepushed all of the terminal barbs 110 into the detent channels 114 to thedesign depth, belts or keeper bands 118 may be translated axially alongthe outside surface of the collet fingers 104 from a retainer positionaround the cylindrical mid-body 102 to a keeper position around thedistal ends of the collet fingers 104. When positioned around the colletfinger ends, the keeper bands 118 prevent the resilient collet fingersfrom flexing to release the barbs 110 from engagement with thetransition collars 60.

In a preferred embodiment of the invention as illustrated by FIG. 3, theassembly of a charge carrier joint 34 comprises a steel transitioncollar 60 secured to each end of a carbon fiber (for example) carrierhousing tube 50. An inner loading tube 38 comprising the shaped chargesis fabricated with an alignment collar 48. The alignment collar keyaperture 56 is angularly oriented with respect to the discharge axis orplane of the shaped charges. Additionally, the seating plane 49 of thecollar is located relative to the detonation boosters 46 with theprecision required to place the detonation boosters 46 of adjacentcarrier joints 34 within detonation proximity upon final assembly.

This positional alignment of the inner loading tube 38 is secured in theaxial directions by a setting ring 76. The setting ring 76 is turnedalong the threads 75 for advancement against the alignment collar 48.Tight engagement of the setting ring 76 against the abutment collar 48longitudinally confines the collar 48 between the setting ring 76 andthe seating ledge 70 of the transition collar 60. The shear key 45penetrates both, the key aperture 56 in the collar 48 and the key slot72 in the ledge 70. This shear key 45 penetration secures the requiredangular orientation of the shaped charges in the inner loading tube 38relative to the transition collar 60 and the alignment bore 90 in thecollar.

Further preassembly of a charge carrier joint 34 may include insertionof one end of a sealing sleeve 82 into the seal bore 78 of the onetransition collar 60 respective to each charge carrier joint 34. Thealignment pin 88 may be inserted through the spacing ring 84 aperture 86and into the collar 60 aperture 90. With one keeper band 118 shiftedaxially over the connector sleeve mid-body 102, the respective colletfingers 104 may flex radially to allow a bayonet penetration of atransition collar 60 respective to a cooperative charge carrier joint 34between the connector sleeve 100 and the internal sealing tube 80.

Description of a representative rig floor assembly of a perforating gunmay begin with a first charge carrier joint 34 suspended within the wellcasing from retainer slips. Although either end of a charge carrierjoint may be held above the slip plane of the rig floor, it will beassumed for this description that the “first” joint is suspended in thewellbore with only the “upper” end transition collar 60 above the rigfloor slip plane and the remainder of the first joint below the slipplane. The “upper” end of the first joint also includes the preassembledsealing tube 80 and the connector tube 100. It is further assumed thatthe keeper band 118 for the “lower” collet fingers 104 has beentranslated over the respective collet finger barbs 110 to secure barbpenetration into the detent channel 114. The keeper band 118 for the“upper” collet fingers 104 has been translated over the sleeve mid-body102. Consequently, the “upper” collet fingers 104 are free to flexradially and receive a bayonet penetration of a transition collar 60respective to a “second” charge carrier joint 34.

A “second” charge carrier joint 34 is added to the first by suspendingthe second joint in axial alignment with the first. On a rig floor, oneend of the “second” charge carrier joint is secured to the rig elevatorblock and lifted to a point that places the other or “lower” end of thesuspended “second” carrier joint axially above the “upper” end of thefirst joint. The adjacent “lower” end of the second joint includes nosealing tube 80 or connector sleeve 100. This second charge carrierjoint 34 is rotationally oriented, (preferably manually) to align thepin 88 that is projecting from the first carrier joint 34 with the bore90 of the second charge carrier joint 34. When the pin 88 is alignedwith the bore 90, the second charge carrier joint is lowered against thefirst to close the ends together by a simple axial translation(lapping).

When the closure is sufficient, the “upper” collet finger barbs 110 onthe first joint connector sleeve 100 will penetrate the detent channel114 of the second carrier joint to latch the two carrier jointstogether. With the barbs 110 in the detent channel 114, the respectivekeeper band 118 may be axially translated from the mid-body portion ofconnector sleeve 100 to a position near the distal ends of the colletfingers 104 thereby preventing the barbs 110 from flexing out of thedetent channel 114. The assembly procedure of this and the foregoingparagraphs defines a basic “bayonet” joint connection or assembly. Morefundamentally, the bayonet mechanism usually includes (1) rotationalalignment of the two joint components about an assembly axis; (2) alinear compressive lapping of the two joint components along theassembly axis; and (3) a spring biased latching of the joint componentsat the desired lap position.

Extraction of a gun from the borehole normally occurs after the shapedcharges have been discharged and the tool is inert. There are occasions,however, that an armed and ready gun must be extracted. In any case, gunextraction generally requires the shaped charge carriers to be separatedat the connector union. Consequently, it is highly desirable for theconnector union between shaped charge carrier joints to be releasedquickly and without undue heat or shock.

For the FIG. 3 invention embodiment, the connector release sequence isillustrated by FIGS. 4 through 6. A unit of the gun assembly, whether asa single carrier joint or as a multiple joint stand, is lifted out ofthe wellbore by the derrick draw-works. As the selected unit issupported by the derrick, slips are set to support the gun portionremaining in the wellbore below the selected unit. The connection ofadjacent transition collars 60 between the selected unit supported bythe derrick and the gun portion suspended below the slips is therebyrelieved of tensile stress. The keeper band 118 respective to the set ofcollet finger barbs 110 to be extracted from their detent channel 114 iseither cut or translated axially over the connector mid-body 102 asillustrated by FIG. 4. With the keeper band 118 removed, the respectivecollet fingers 104 are free to flex away from the adjacent collarsurface. A disassembly tool 92 having a tapered leading edge 94 may bepositioned against the body ring 64 of one such transition collar 60 andforced against the tapered end-face 116 of a collet finger. As theleading edge 94 of the disassembly tool 92 advances, as shown by FIG. 5,the collet barb 110 is lifted out of the detent channel 114. When all ofthe barbs 110 on the connector sleeve 100 are lifted clear of the detentchannel 114, the gun unit supported by the derrick draw-works may belifted clear of the gun portion remaining in the wellbore suspended fromthe rig floor slips as represented by FIG. 6.

To lift all of the collet barbs 110 from the detent channel 114simultaneously, the disassembly tool blade 92 may take the general formof a cylindrical annulus such as a section of pipe having an internaldiameter slightly larger than the external diameter of the collar bodyring 64. The cylindrical wall of the disassembly tool 92 may be splitlongitudinally along diametrically opposite lines and the two-halfcylinders joined by a hinge along one of the split lines. This hingedconnection of the two half-cylinders allows the tool 92 to be opened forpositioning against the collar 60 and closed to embrace the fullcircumference of the collar and to thereby engage all of the colletfinger barbs 110 simultaneously.

The transition collar embodiment of FIGS. 11 and 12 is similar to thatof the FIG. 3 embodiment except for the swaging skirt interface. ThisFIG. 11 embodiment provides an interface skirt 120 having a belled ortapered inside surface 122 faced with a fine, (24 threads/in. forexample), female thread 124. The mating end segment 126 of a housingtube 50 may be formed with a correspondingly tapered, external or malethread 125. It is not essential for the respective thread faces to mesh.The primary bonding mechanism of the threads is to increase thecontiguous surface area of the mating elements. The thread face 124 ofthe collar skirt 120 is turned onto or pressed against the threaded endof the housing tube with a coating of uncured epoxy, for example, inbetween. Preferably, the interface is held under compressive pressure asthe boundary film of epoxy between the adjacent threads is cured.

The carrier joint connector embodiment of FIGS. 13, 14 and 15 comprisesmany characteristics of the FIG. 3 embodiment. A particularly notabledifference, however, is that the transition collar at one end of acharge carrier joint differs from the transition collar at the oppositeend of the same charge carrier joint. Another notable difference is thatsome rotational drive of a threaded connector sleeve 130 is required tocomplete the joint assembly.

Referring to FIGS. 13 and 15, the collar 134 is distinguished by athreaded interface 132 between a connector sleeve 130 and a transitioncollar body 134. The mating transition collar, 136, provides acircumferential snap ring 138 seated in a circumferential slot 140. Aportion of the snap ring 138 annulus projects radially beyond thereduced diameter surface 142 of the collar 136 body to provide a loadsupporting ledge.

The internal cylinder bore 146 of connector sleeve 130 is under-cutbetween the internal thread 132 and an annular bearing face 148 at thedistal end of the sleeve 130. The I.D. crest of the sleeve threads 132is greater than the O.D. of the slot engaged snap ring 138 whereby thesleeve may be translated axially along transition collar 136 by passingthe internal threads 132 of the sleeve 130 over the O.D. of the snapring 138. With the connector sleeve 130 surrounding the collar 136 butdisplaced along the reduced diameter body surface 142 to expose the slot140, the snap ring 138 may be positioned in the slot 140. Translation ofthe sleeve 130 in the opposite direction toward the end of the collar136 is thereby restricted by an interference engagement of the sleevebearing face 148 with the projecting annulus of the snap ring 138.

Both collars 134 and 136 have smooth inside bores 135 and 137 toaccommodate the O-ring seals 108 of an internal sealing tube 80. Asdescribed with respect to the FIG. 3 embodiment, the two collars arerotationally oriented by an alignment pin 88.

FIG. 15A represents an alternative embodiment 160 of an internal sealingtube which includes an integral construction of the sealing sleeve 162with the spacing ring 164. In lieu of O-ring seals, however, the outsidesurfaces of the oppositely extended sealing sleeve 162 are tapered to becompressed to an interference seal against the inside edge of therespective collar end-faces 143 and 144.

When a pair of transition collars 134 and 136 as shown by FIG. 15 are tobe mated for assembly, the sleeve 130 has preferably been previouslysecured to the collar 136 by the snap ring 138. When the two collarends, 134 and 136, are axially and angularly aligned, the sleeve 130 istranslated along the reduced diameter body 142 of the collar 136 androtated to mesh the threaded interface 132 with collar 134. The thread132 engagement length and other dimensions of the assembly arecoordinated to translate compressive engagement of the sleeve bearingface 148 against the snap ring 138 to a compression of the spacing ring84 between the collar end-faces 143 and 144.

As best illustrated by FIG. 13, the collar end-faces 143 and 144 clampagainst the sealing tube ring 84, the end-face 145 of the sleeve 130compresses a lock ring or washer 147 against a thread root shoulder 149on the collar 134. Notches 150 in the sleeve end-face 145 and notches155 in the thread root shoulder 149 cooperate with lock ring tabs 152 tooppose any tendency of the sleeve 130 to rotate against the assemblyunder operational stress.

Disassembly of this FIG. 13 embodiment is enabled by either bending thelock ring tabs 152 out of the notches 150 or 155 or by cutting the lockring 147. This procedure permits the sleeve 130 to be rotated over thethreads 132 until free for translation away from the threaded collar134. The sleeve 130, nevertheless remains captured around the transitioncollar 136 by the snap ring 138.

Another embodiment of the invention may take the form illustrated byFIGS. 16 through 19. In this embodiment, the transition collars 170 areidentical for both ends of a carrier housing joint. Within a reducedoutside diameter end portion (FIGS. 18 and 19), each collar 170 includesone or more external O-ring seals 174 positioned between the respectivecollar end-face and a detent channel 172. Angular orientation betweentwo joining collars 170 may be achieved by one or more alignment pins 88that penetrate respective apertures 86 in the collar end-faces asillustrated by FIGS. 17 and 18. Alternatively, the two collars 170 mayalso be angularly oriented in the manner illustrated by FIG. 19 whichrelies upon a perimeter key 157 projecting from the end-face of onecollar 170 to mesh with a perimeter slot 159 in the cooperative collarend-face. Notably, this perimeter key and slot means for angularlyorienting the FIG. 19 invention embodiment may be applied equally wellto the embodiments of FIGS. 3, 13, 20 and 25.

The union of the two collar 170 end-faces is secured by a connectorsleeve 176. The embodiment illustrated by FIGS. 16 through 19illustrates collars 170 as having a slip fit assembly relationship overthe reduced outside diameter end portion 171 of the collars. It will beunderstood, by those of skill in the art that the reduced diameterend-portion of a connector merely allows a reduced outside diameter forthe sleeve 176. The invention embodiment may also be effectivelypracticed with no reduced diameter on the collar end portions and theconnector sleeve 176 having an inside diameter greater than the outsidediameter of collars 170.

The connector sleeve 176 length is selected to span axially past bothdetent channels 172 when the collar end-faces are abutting. A rollswaging tool, not shown, is used to press, e.g. swage, a channel bead178 of the sleeve material into the respective detent channels 172.Preferably, a sleeve 176 is preassembled with one collar of a carrierjoint prior to rig floor assembly. Consequently, when a rig floorconnection is made, one channel bead 178 has already been swaged. On therig floor, therefore, it is necessary, only to rotationally align thejoints and function a swaging tool for the other channel bead 178.

Separation of the union between two charge carrier joints 34 joined by aswaged sleeve 176 may, for example, be quickly accomplished by atraditional pipe cutting tool, not shown. Since the sleeve 176 has asimple and inexpensively fabricated configuration, consumptivedestruction of the sleeve 176 usually is an acceptable assembly expense.

Another configuration of the invention, similar to that of FIGS. 16through 19, may take the form of that illustrated by FIGS. 20 through24. Transition collars 170 are substantially identical for both ends ofthe charge carrier joint. Angular orientation about the axis 44 may besecured by either alignment pins 88 (FIGS. 20 and 23) or a perimeter key157 and slot 159 (FIG. 24). Along the length of the reduced diameter endportion 171, a retaining ring slot 182 is cut to accommodate the fullvolume of a retaining ring 184.

The connector sleeve 180 for this FIG. 20 through 24 embodiment includesring retention channels 186 around the inside perimeter inlongitudinally spaced alignment with the snap ring channels 182 when thetwo transition collars 170 of a union have abutting end-faces.

The snap rings 184 are partial circles of resilient steel, for example,having an incomplete circular perimeter at a neutral, unstresseddiameter. The neutral or unstressed outside diameter of the snap rings184 generally corresponds to the root or greatest diameter of theretention channels 186 in the sleeve 180. The root or least diameter ofthe snap ring channels 182 corresponds to the inside diameter of a snapring 184 when stressed to close a perimeter gap. When the perimeter gapis closed, the outside diameter of the ring 184 is equal to or less thanthe outside diameter of the collar end portion 171 as shown by FIGS.22-24. The volumetric capacity of a snap ring channel 182 is sufficientto accommodate the entire volume of the ring 184 whereby the outsidediameter elements of the snap ring 184 are radially at or below theoutside diameter surface elements of the collar end portion when thering is collapsed.

In radial plane alignment with the ring retention channel 186, aplurality of threaded apertures 188 are bored to penetrate the connectorsleeve wall between the outside perimeter surface and the root diametersurface of the ring retention channel 186. As shown by FIG. 22, thesethreaded apertures 188 may be provided with set screws 189 and are,axially, outside of the O-ring sealed space.

Placement of the snap rings 184 in the ring channels 182 is apreassembly function. When a secure union between abutting collars 170is required, the set screws 189 are removed from the volumetric space ofthe retention channel 186. Moreover, it is preferable to have no setscrews in the apertures 188 during the assembly process. When angularlyaligned to permit collar end face abutment, upon compressive assemblyforce the ramped end faces 181 of the connector sleeve 180 will radiallycollapse the rings 184 into the volumetric space of channels 182 untilthere is an alignment with the sleeve retention channels 186. Whenradially aligned, the resilient bias of a ring 184 enlarges the ringdiameter into the volume of a respective retention channel 186. The ring184 expansion, however, is only sufficient to bridge the interfacebetween the outside diameter of the collar 170 and the inside diameterof the sleeve 180 as illustrated by FIG. 20. The neutral or unstressedvolume of the ring 184 penetrates a portion of the volumetric space ofboth channels, 182 and 186. The ring must therefore be sheared forfurther axial translation between the sleeve 180 and a collar 170.

Disassembly of a union is accomplished by installing and turning the setscrews 189 inwardly against the snap ring 184 to collapse it against theroot diameter surface of the channel 182 as shown by FIG. 22. A small,axial disassembly force against the respective collars 170 will overcomethe frictional interface between the set screws 189 and the snap ring184 to permit and axial disassembly translation between the two.

Those of skill in the art will understand that the set screw disassemblyprocedure described above merely represents one mechanical procedure forcollapsing the internal snap ring 184. In lieu of set screws, the snapring 184 may also be collapsed by a portable tool not illustrated thatprovides a radially oriented circle of hydraulically driven needlepunches to penetrate the apertures 188. Although the drawings illustratea multiplicity of set screws 189 around the connector sleeve 80perimeter, it will be understood that only two or three set screws 189or needle punches may be effective to sufficiently compress the snapring 184 for disassembly of the union.

The connector embodiment of FIGS. 25 and 26 between transition collars190 is angularly oriented by one or more alignment pins 88 thatpenetrate receptacle apertures 86 in the adjacent collar end-faces. At apredetermined distance from each collar end-face, a detent channel 192is formed into the internal perimeter of the collar. Linking twotransition collars 190 for a joint union is an internal collet connector200. The collet connector 200 comprises an external collar 202projecting radially out from the approximate mid-length of an internalsealing sleeve 206. Notches or apertures 204 across the collar 202 widthaccommodate a traverse of the alignment pins 88 past the collar 202.

The sealing sleeve 206 carries O-ring seals 208 on opposite sides of thecollar 202 to engage the inside diameter surfaces of the respectivetransition collars 190. Projecting as integral extensions from theopposite ends of the sealing sleeve 206 are resilient collet fingers210. Each collet finger 210 is terminated by a barb 211 having a rampedend-face 212.

Rig floor joint assembly of the FIGS. 25 and 26 embodiment assumes apreassembly of the internal collet connector 200 with one of thetransition collars 190 respective to a joint union. The union isaccomplished by an axial and rotational alignment of the two jointsfollowed by a compressive translation between the joints. No disassemblymeans is provided for this embodiment.

FIGS. 27 and 28 illustrate a preferred embodiment of the internalloading tube 38 as configured for assembly with all embodiments of theinvention and as particularly illustrated with respect to the FIG. 3invention embodiment. As designed for Controlled Buoyancy Perforating,the body of the inner loading tube 38 that provides direct contactalignment with a multiplicity of shaped charges 58 may be formed of avery light weight material such as a foamed plastic or glass. Thispreformed or molded body also encloses the fusing mechanism not shownfor detonating each of the charges 58. The fusing mechanism links thedetonation boosters 46 at opposite ends of the loading tube.

Critical dimensions in the loading tube 38 design and fabricationinclude the overall length of the tube relative to the opposite endfaces of the charge carrier joint 34. When assembled, the boosters 46must be within detonation transfer proximity of each other. To this end,the plane of seating ledge 70 is placed in relation to the joint endface to cooperate with the abutment face 49 of the alignment collar 48.The alignment collar 48 is secured to the length of the loading tube 38body by such means as to maintain the required axial alignmentthroughout the downhole placement process.

When the internal loading tube 38 is inserted along the bore of acarrier housing 36, the surface 49 makes a contiguous planar engagementwith the surface of seating ledge 70 in the transition collar 60. Thisplanar abutment is secured by the threaded setting ring 76. If theinternal diameters of the collar mandrels 60 are coordinated to a slipfit accommodation of the loading tube 38 outside diameter, no additionalposition control mechanism may be necessary. The union of two joints 34necessarily aligns the shaped charge 58 discharge plane and places therespective detonation boosters 46 of a joint union within ignitionproximity. Obviously, and internal snap ring not shown may besubstituted for the threaded setting ring 76.

Although numerous embodiments of the invention have been described indetail, it will be recognized by those of ordinary skill in the art thatnumerous additional embodiments and permutations may be inspired bydescriptions presented. In particular, those of skill in the art willrecognize that the various invention features and characteristicsdistinctive to the metal collars respective to each of the severalinvention embodiments disclosed herein may be formed as integralelements of a composite pipe. Such features and/or characteristics maybe molded or machined into an integrated composition. For example, thedetent channels 172 of the FIG. 17 embodiment may be molded or turnedinto a composite pipe wall. Definition of the invention, therefore, isrepresented by those overarching principles described by the appendedclaims.

1. A shaped charge carrier joint comprising the assembly combination ofan inner loading tube disposed within an external housing, said innerloading tube providing a direct seating structure for shaped chargeunits and for corresponding ignition means linking detonation boostersat opposite distal ends of said inner loading tube, said externalhousing having a circumferential detent channel proximate of oppositedistal ends of said external housing, a sleeve circumscribing anexternal perimeter of a housing distal end and fluid sealing meansbetween an inside surface of said sleeve and an outside surface of saidhousing distal end, said sleeve being secured to one of said distal endsby the swaged beading of a portion of said sleeve into the respectivedetent channel.
 2. A shaped charge carrier joint comprising theend-to-end assembly of a pair of external housing tubes, each housingtube having an inner shaped charge loading tube therein, each housingtube of said pair having a circumferential detent channel proximate ofrespective joint ends, a sleeve bridging said joint to overlie both ofsaid detent channels and a bead of said sleeve swaged into each of saiddetent channels to secure a structural joint between said housing tubes.3. A shaped charge carrier joint as described by claim 2 furthercomprising means for sealing an interface between an inside surface ofsaid sleeve and an outside surface of said housing tubes from fluidpenetration.
 4. A shaped charge carrier joint as described by claim 2wherein said sleeve overlies a reduced external diameter portion of saidhousing tube ends, said detent channels being within said reduceddiameter portion.
 5. A shaped charge carrier joint as described by claim2 wherein a predetermined angular orientation between said pair ofexternal housing tubes is secured by an alignment pin.
 6. A shapedcharge carrier joint as described by claim 2 wherein a predeterminedangular orientation between said pair of external housing tubes issecured by an alignment key.